Professional Documents
Culture Documents
Floboss™ 503 and 504 Flow Managers: Instruction Manual
Floboss™ 503 and 504 Flow Managers: Instruction Manual
NOTICE
Remote Automation Solutions, a division of Emerson Process Management shall not be liable for technical or editorial errors in this manual
or omissions from this manual. REMOTE AUTOMATION SOLUTIONS MAKES NO WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT
TO THIS MANUAL AND, IN NO EVENT SHALL REMOTE AUTOMATION SOLUTIONS BE LIABLE FOR ANY INCIDENTAL, PUNITIVE,
SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS
OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND
CLAIMS OF THIRD PARTIES.
Bristol, Inc., Bristol Babcock Ltd, Bristol Canada, BBI SA de CV and the Flow Computer Division are wholly owned subsidiaries of Emerson
Electric Co. doing business as Remote Automation Solutions, a division of Emerson Process Management. FloBoss, ROCLINK, Bristol,
Bristol Babcock, ControlWave, TeleFlow and Helicoid are trademarks of Remote Automation Solutions. AMS, PlantWeb and the PlantWeb
logo are marks of Emerson Electric Co. The Emerson logo is a trademark and service mark of the Emerson Electric Co. All other
trademarks are property of their respective owners.
The contents of this publication are presented for informational purposes only. While every effort has been made to ensure informational
accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described
herein or their use or applicability. Remote Automation Solutions reserves the right to modify or improve the designs or specifications of
such products at any time without notice. All sales are governed by Remote Automation Solutions’ terms and conditions which are available
upon request.
Remote Automation Solutions does not assume responsibility for the selection, use or maintenance of any product. Responsibility for
proper selection, use and maintenance of any Remote Automation Solutions product remains solely with the purchaser and end-user.
© 1997-2011 Remote Automation Solutions, division of Emerson Process Management. All right reserved.
ii Rev 11/11
FloBoss 503 and 504 Instruction Manual
Table of Contents
Index ................................................................................................................................I-1
The FloBoss computes gas flow for both volume and energy. The FloBoss provides on-site
functionality and supports remote monitoring, measurement, data archival, communications, and
control. The FloBoss design allows you to configure specific applications including those requiring
gas flow calculations, data archival, remote communications, and logic and sequencing control using a
Function Sequence Table (FST).
Physically, the FloBoss consists of a printed-circuit Main Electronics Board and a display housed in a
compact, weather-tight case. The FloBoss is packaged in a National Electrical Manufacturer’s
Association (NEMA 4) windowed enclosure that can mount on a wall or a pipestand. A cover is
provided for the display to protect it from adverse weather conditions. Refer to Figure 1-1 and Figure
1-2.
The steel enclosure protects the electronics from physical damage and harsh environments. The
enclosure consists of two pieces: the body and the door. A foam-rubber gasket seals the unit when the
hinged door is closed. The hinge, located on the left side, is stainless steel and fastened to the body
with machine screws, allowing removal of the door. The door secures with a lockable hasp.
The enclosure is fabricated from carbon steel. Refer to the Specifications tables in Section 1.6,
FloBoss 503 and FloBoss 504 Main Specifications, on page 1-20 for dimensional details.
Mounting Flange
LCD
Cover
Sensor
Operator
Interface (LOI)
Connector
Figure 1-1. FloBoss 503 Flow Manager
LCD
Cover
Operator
Sensor
Interface (LOI)
Connector
Figure 1-2. FloBoss 504 Flow Manager
1.3.1 Hardware
The Main Electronics Board mounts on quick-fastener stand-offs located on top of the swing-out panel.
The majority of the components are surface-mounted with only the top side of the board used for
components. The Main Electronics Board has built-in I/O capabilities, an LCD display, provisions for
an optional communications card, and provisions for an optional I/O card. For more information on the
Main Electronics Board, refer to Section 1.5.1, Main Electronics Board Overview, on page 1-13.
The built-in inputs and outputs (I/O) on the FloBoss consist of a port for a Sensor, a 4-wire Resistance
Temperature Detector (RTD) input interface, and a Discrete Output (DO). Three diagnostic Analog
Inputs are dedicated to monitoring battery voltage, charger voltage, and enclosure/battery temperature.
Refer to Section 1.5, Product Electronics, on page 1-13 for more information.
On the FloBoss 503, the orifice-metering Sensors measure differential pressure and static pressure
(absolute or gauge) by converting the applied pressure to electrical signals and making the readings
available to the Main Electronics Board. The Sensor housing fastens to a flanged adapter, which in
turn mounts with four bolts to the bottom of the enclosure. The Sensor cable plugs directly into the
Main Electronics Board. For more information on the Sensor for the FloBoss 503, refer to Section 6.
On the FloBoss 504, the turbine-metering Sensor Module (SM) measures pulses and static pressure by
electronically counting pulses and converting the applied pressure to electrical signals. It makes the
readings available to the Main Electronics Board. The Sensor Module housing mounts with four bolts
to the bottom of the enclosure. The Sensor Module cable plugs directly into the Main Electronics
Board. For more information on the Sensor Module for the FloBoss 504, refer to Section 7.
The I/O parameters, sensor inputs, flow calculations, power control, security, and FST programm-
ability are configured and accessed using the ROCLINK for Windows software. Refer to the
ROCLINK for Windows Configuration Software User Manual (Form A6091), for details concerning
software capabilities.
A variety of plug-in communication cards are available that allow you to customize the FloBoss
installation for most communications requirements. The communication cards provide an interface
for the host communications port (Comm1). These cards permit serial communication protocols, as
well as dial-up modem communications. Refer to Section 4, Communications Installation and wiring,
for more information.
A radio with an integral modem can also be mounted inside the FloBoss enclosure using the optional
radio bracket. Refer to Section 2, Installation and Use. The radio bracket allows a radio up to 57.15
mm (2.25 inches) high to be mounted securely in the battery compartment inside the FloBoss
enclosure. Power for the radio can be controlled through the EIA-232 (RS-232) communications card.
Clearance is provided for the radio antenna cable to exit through the bottom of the enclosure.
An optional FloBoss 500-series I/O Cards provide additional inputs and outputs for expanded
monitoring and control applications. The I/O Card contains Analog Inputs (AI), an Analog Output
(AO), Discrete Inputs (DI), Pulse Inputs (PI) and Discrete Outputs (DO). The DI, DO, and PI
circuitry is optically coupled to help isolate the processor board from the input signal. Refer to
Section 4, Communications Installation and Wiring, for more information.
The intrusion switch acts as a tamper detector for the FloBoss units. The intrusion switch is a
momentary contact switch used to detect whether the door to the enclosure is open or closed. The
switch, which has a normally-closed contact, is designed to be mounted in the FloBoss enclosure.
Refer to the ROC/FloBoss Accessories Instruction Manual (Form A4637) for details. An I/O Card
must be installed in order to use the intrusion switch. The status of the switch can be configured to
generate an alarm when the door to the enclosure is open. Refer to Section 5, Inputs and Outputs, for
details.
The FloBoss enclosure can hold up to four sealed lead-acid batteries. The 12-volt batteries provide
approximately 7 Amp-hours each, resulting in up to 28 Amp-hours of backup capacity or up to 21
Amp-hours of backup capacity when used with an AC power supply. The batteries are mounted under
the electronics swing-out panel and are retained by the panel when it is secured. The batteries are
connected to a wiring harness that allows the batteries to be changed without removing power from
the unit. Refer to Section 2, Power Connections, for further details.
A solar panel can be installed to recharge the backup batteries; it connects to the POWER charge
inputs on the Main Electronics Board. Circuitry on the Main Electronics Board monitors and
regulates the charge based on battery voltage, charging voltage, and temperature. The typical panels
used are 12-volt panels with output ratings of 5 or 10 watts. The panels are typically bracket-mounted
on a pole or pipe, and the wiring is brought into the bottom of the FloBoss enclosure through a liquid-
tight fitting. Refer to Section 3, Power Connections, for further details.
1.4.1 Firmware
The firmware, contained in flash ROM on the electronics board, determines much of the functionality
of the FloBoss, such as:
♦ Memory logging of 240 alarms and 240 events.
♦ Archival of data for up to 15 history points for up to 35 days.
♦ AGA flow calculations.
♦ Power cycling control.
♦ Flow calculations for a single meter run.
♦ Logic and sequencing control by means of two user-defined Function Sequence Tables (FST).
♦ Closed-loop (PID) control.
♦ Communications based on either ROC protocol or Modbus protocol (slave mode only).
♦ Spontaneous Report by Exception (SRBX) communication to a host computer.
♦ User level security.
The primary inputs used for the orifice metering flow measurement function are differential pressure,
static pressure, and temperature. The differential and static pressure inputs, which are sampled once
per second, come from a Dual-Variable Sensor (DVS) or a Multi-Variable Sensor (MVS). The
temperature input, which is sampled and linearized once per second, comes from an Resistance
Temperature Detector (RTD) probe.
The primary function of the FloBoss 504 is to measure the flow of gas using a turbine meter (with a
single or dual pulse train), in accordance with the American Gas Association (AGA), American
Petroleum Institute (API), and International Standards Organization (ISO) standards.
The primary inputs used for turbine flow measurement are Pulse Input (PI) counts, static (line)
pressure, and temperature. The PI counts are acquired from a turbine meter, the static pressure
(including auxiliary pressure) input comes directly from the Sensor Module, and the temperature input
is read directly by the FloBoss unit from an RTD probe.
Flow Time
The differential pressure stored for each second is compared to the configured low flow cutoff. If the
differential pressure is less than or equal to the low flow cutoff or the converted static pressure is less
than or equal to zero, flow is considered to be zero for that second. Flow time for a recalculation
period is defined to be the number of seconds for which the differential pressure exceeded the low
flow cutoff.
Flow time averages of the inputs and the flow extension over the configured recalculation period are
calculated, unless there is no flow for an entire recalculation period. Averages of the inputs are
recorded to allow monitoring during no flow periods.
After power-up, the Master Controller Unit (MCU) enters the normal operation mode. The Sensor
Module (SM) then counts the pulses as they occur. Once every 992 ms, the SM reports to the MCU
the number of pulses received by its pulse inputs, as well as the static and auxiliary pressures. The
values are stored in temporary memory.
Once every Scan Period, the MCU processes the pulse counts, determines the number of pulse counts
since the last reading, and calculates a rate. Next, the static pressure and auxiliary pressure values are
read. Then the temperature is read and linearizing compensation is applied to the pressure readings if
necessary. The RTD is internally re-calibrated for every 5°C (9°F) change as sensed by the enclosure
temperature diagnostic input.
All resultant values are stored in the current value database. The values are taken from the current
value database and used to calculate the Minute, Hour, and Daily historical values.
Finally, the MCU enters a low-power mode and waits for the beginning of the next cycle.
Once a minute and once an hour, the values are logged along with other configured values to the
Historical Database. At the configured Contract Hour, the values are stored to the Daily Historical
Log and zeroed for the start of a new day.
History
Point Value Archive Type
Number
1 Flowing Minutes Today Accumulate
FloBoss 503 – Differential Pressure Average
2
FloBoss 504 – Raw pulse count from Pulse Input Primary Device Totalize
3 Static or Line Pressure Average
4 Temperature Average
FloBoss 503 – IMV, Integral Multiplier Value, or C Prime Average
5
FloBoss 504 – BMV, Base Multiplier Value, or C Prime Average
FloBoss 503 – Pressure Extension or IV, Integral Value Average
6
FloBoss 504 – Uncorrected Flow Today Accumulate
7 Instantaneous Flow Accumulate
8 Instantaneous Energy Accumulate
The seven user-configurable history points and Averaging Technique may be configured in ROCLINK
for Windows software.
The time stamp for periodic logging consists of the month, day, hour, and minute. The exception is
for FST Second logging, for which the time stamp consists of the day, hour, minute, and second.
In addition to providing functionality for appending new alarms to the Alarms Log, it allows host
packages to request the index of the most recently logged alarm entry. Alarm logging is available
internally to the system, to external host packages, and to FSTs. Alarm Logs are not stored to the flash
ROM during the Save Configuration function in ROCLINK for Windows software.
The Alarm Log operates in a circular fashion with new entries overwriting the oldest entry when the
buffer is full. The Alarm Log provides an audit history trail of past operation and changes. The Alarm
Log is stored separately to prevent recurring alarms from overwriting configuration audit data.
The system Event Log has the capacity to maintain and store up to 240 events in a circular log. The
Event Log has information fields, which include point type, parameter number, time and date stamp,
Point Number (if applicable), the operator identification, and either the previous and current parameter
values or a 14-byte detail string in ASCII format.
In addition to providing functionality for appending new events to the Events Log, it allows host
packages to request the index of the most recently logged event entry. Event logging is available
internally to the system, to external host packages, and to FSTs.
Event Logs are not stored to flash ROM when the Save Configuration function is issued in ROCLINK
for Windows software. The Event Log operates in a circular fashion with new entries overwriting the
oldest entry when the buffer is full. The Event Log provides an audit trail history of past operation
and changes. The Event Log is stored separately to prevent recurring alarms from overwriting
configuration audit data.
1.4.4 Security
The FloBoss unit provides for security within the unit. A maximum of 16 log-on identifiers (Operator
IDs) may be stored. In order for the unit to communicate, the log-on ID supplied to the ROCLINK for
Windows software must match one of the IDs stored in the FloBoss unit. The Local Port (Security on
LOI) has security Enabled by default. The Host Port (Comm1) can likewise be configured to have
security protection, but is disabled by default. Refer to the ROCLINK for Windows Configuration
Software User Manual (Form A6091) concerning security.
1.4.6 Modbus
The Modbus Protocol Emulation Program is contained within the FloBoss firmware. The Modbus
application is designed to allow the FloBoss unit to emulate on the Host Port (Comm1) the
communications protocol used by Modbus devices. The Modbus communications protocol is fully
described in the reference guide entitled “Modicon Modbus Protocol Reference Manual” publication
PI-MBUS-300 (not available from Emerson Process Management).
The Modbus protocol supports two modes of transmission: American Standard Code for Information
Interchange (ASCII) and Remote Terminal Unit (RTU), with RTU as the default. Both modes of
transmission are supported by the FloBoss unit. In addition, a version of Modbus with EFM
extensions can be emulated as a slave device. Refer to the ROCLINK for Windows Configuration
Software User Manual (Form A6091) for details.
The Power Control function calculates which zone should be currently active. In Second mode, the
Power Control begins in the ON state and continues with a full On Time and then goes to the OFF
state for the full Off Time. In Minute mode, the Power Control determines if it should be ON or OFF
and how much time it needs until it switches. Refer to Section 3, Power Connections and Section 4,
Communications Installation and Wiring.
The Main Electronics Board has 512 KB of static random access memory (SRAM) for storing
interrupt vectors, Function Sequence Tables (FST), alarms, events, and history data.
The Main Electronics Board also has a 512 KB flash memory chip for storing the operating system
factory code and configuration parameters. Two of the 64 KB blocks are reserved for internal usage.
The built-in LCD provides the ability to look at data and configuration parameters while on site
without using the Local Port (LOI) and a PC. Through this display, you can view predetermined
information stored in the FloBoss. Up to 16 items can be defined for display. The LCD automatically
cycles through the configured list of items displaying a new value approximately every three seconds.
The first two displays, which cannot be configured by the user, show values for time and date,
operating voltages, and battery condition. The next five displays are configured by the factory to
show certain flow parameters, but you may change their configuration. Refer to the ROCLINK for
Windows Configuration Software User Manual (Form A6091) for details on how to configure the list
of values for the LCD panel.
J1
NORM Reset
RST
Jumper (P1)
Super
Capacitor Liquid Crystal
"Battery" Display (LCD)
C3
U8
U7
I/O Card
Connector U9 CLOCK
PROCESSOR
FLASH
68LC302
U6
U11
RTD
A/D
U12
CR6 CR7
MV1
CR9
PT1
PT2 PT3
FL1 MV2
P9 P10
P8
P11
DOC0331B
Sensor Connector
NOTE: The following installation should not be used in Class 1, Division 2 hazardous
(C1D2) areas.
A cannon-type waterproof connector on the bottom of the enclosure provides connection through a
prefabricated cable for a Local Port device, typically a personal computer (PC) running ROCLINK for
Windows software. Inside the FloBoss enclosure, the cannon-type connector is wired to three
terminals (LOI) on the Main Electronics Board.
For installations using radio communications, battery power can be conserved by cycling power to the
radio or a cellular telephone. The power cycling control for a radio is acquired through the Data
Terminal Ready (DTR) signal on the optional EIA-232 (RS-232) communications card. Refer to the
ROCLINK for Windows Configuration Software User Manual (Form A6091) concerning radio power
control. The radio is connected to the signal wiring terminals located on the EIA-232 (RS-232)
communications card. Refer to Section 4, Communications Installation and Wiring.
The communications connectors on the Main Electronics Board provide the FloBoss unit with
electrical access and mounting provisions for the optional communications cards. The
communications cards mount directly on the connectors at P3 on the Main Electronics Board and are
held in place with three compression stand-offs. The stand-offs on the Main Electronics Board pass
through the communications card. The communications cards available for the FloBoss unit allow the
options of serial data communications and modem communications. Refer to Section 4,
Communications Installation and Wiring.
The built-in Discrete Output on the FloBoss unit is intended to perform sampler or odorizer functions,
but may be used as a standard DO. This includes toggle mode, latched mode, and timed DO mode.
The Discrete Output is accessed by ROCLINK for Windows software as DO Point Number A4.
When the Sampler function is enabled, the FloBoss unit provides a Time Duration Output (TDO)
based on the volume. A control volume and a pulse duration must be specified with the Sampler
function. After each flow calculation, an internal volume accumulator is compared to the control
volume. If the accumulator exceeds the control volume, a pulse is output and the accumulator is
reduced by the control volume. This output may be used to drive an external totalizer, odorizer, gas
sampler, or similar device. Refer to Section 5, Inputs and Outputs.
During operation, the RTD is read once per second. The value from the RTD is linearized, and then it
is sent to processing as Analog Input (AI) Point Number A3. The AI routine converts this value to
engineering units, performs calibration corrections, and checks alarming. The board temperature is
monitored by the RTD routine. If the temperature has changed by roughly 5°C (9°F), the RTD
circuitry is sent a command to re-calibrate its reference. Refer to Section 5, Inputs and Outputs.
Standby – This mode is used during periods of inactivity. When the operating system cannot
find a task to run, the FloBoss unit enters Standby mode. Processor loading is calculated by
using the amount of time spent in Standby mode. This mode keeps the clocks running and
communications active with baud clocks running. A Periodic Interrupt Timer (PITR) wakes
up the FloBoss unit and starts the normal operating mode.
Sleep – This mode is used if a low battery voltage is detected. The battery voltage measured
by diagnostic Analog Input Point Number E1 is compared to the LoLo alarm limit
associated with this point. This limit value defaults to 10.6 volts.
If the battery voltage is less than the LoLo Alarm configured for AI Point Number E1, the unit:
1. Sets the Real-Time Clock (RTC) alarm for 15 minutes from the present time if a charge
voltage (AI Point Number E2) is greater than the battery voltage (AI Point Number
E1), or for 55 minutes if the charge voltage is less than the battery voltage.
2. Writes the message “Low Battery, Sleep Mode” to the LCD.
3. Enters the Sleep mode.
4. Shuts down communications.
5. The unit wakes up from Sleep mode by the Real-Time Clock alarm (set in Step 1) and
rechecks the voltage to see if operation is possible. If the voltage is greater than the
LoLo Alarm limit for AI Point Number E1, a normal restart sequence initiates.
For the FloBoss unit to be approved for hazardous locations, it must be installed according to the
National Electrical Code (NEC) Article 501.
When installing units in a hazardous area, make sure all installation components selected
are labeled for use in such areas. Installation and maintenance must be performed only
when the area is known to be non-hazardous. Installation in a hazardous area could result
in personal injury or property damage.
2.2 Mounting
When choosing an installation site, be sure to check all clearances. Provide adequate clearance for the
enclosure door to be opened for wiring and service. The door is hinged on the left side. The LCD
display should be visible and accessible for the on-site operator. When using a solar panel, allow
adequate clearance. View of the sun should not be obstructed. Allow adequate clearance and an
obstructed location for antennas, when using radios.
The Sensor is factory-mounted directly to the FloBoss enclosure with four bolts. On the FloBoss 503,
this mounting uses a special coupler to join the Sensor to the four-bolt mounting pattern on the bottom
of the FloBoss enclosure.
♦ Wall or panel mounted – Fasten to the wall or panel using the mounting flanges on the
enclosure. Use 5/16-inch bolts through all four holes. Mounting dimensions are given in
Figure 2-1.
Do not mount the FloBoss unit with the Sensor supporting the entire weight of the unit (such
as in Integral Orifice mounting for the FloBoss 503). Due to the weight of the unit with
batteries and possibly a radio, the unit does not meet vibration requirements unless it is
installed using its enclosure mounting flanges. This could result in damage to the FloBoss
unit or enclosure.
With either mounting method, the pressure inputs must be piped to the process connections on the
Sensor. For more information on process connections, refer to Section 6 for the FloBoss 503 or to
Section 7 for the FloBoss 504.
2X .44
13.80
14.00
18.12
TM
DOC0278C
The FloBoss unit must be mounted vertically with the Sensor at its base. Refer to Figure 2-1
and Figure 2-2. Mounting in other orientations could result in damage to the FloBoss unit
or enclosure.
2X .44
13.80
14.00
16.56
TM
1.56
2.3 Configuration
The FloBoss 500-series Flow Managers have a number of software settings, called parameters, which
must be configured before it is calibrated and placed into operation. Configuration must be performed
using ROCLINK for Windows software, which runs on an personal computer. The PC is normally
connected to the Local Port (LOI) of the flow computer to transfer configuration data into the FloBoss
unit, although much of the configuration can be performed off-line and later downloaded into the unit.
The configuration data can be downloaded into the FloBoss while in the office or in the field.
Although configuration changes can be made remotely via the Host Port (Comm1), it is not
recommended except for minor changes, due to the possibility of data being corrupted during
transmission.
Default values for all parameters exist in the firmware of the FloBoss. If the default firmware
configuration is acceptable for your application, it can be left as is.
It is important to check the input power polarity before turning on the power. Incorrect
polarity can damage the FloBoss unit.
When installing equipment in a hazardous area, ensure that all components are approved
for use in such areas. Check the product labels. Change components only in an area known
to be non-hazardous. Performing these procedures in a hazardous area could result in
personal injury or property damage.
2.4.1 Startup
Apply power to the FloBoss unit by plugging the input power terminal block into the connector
labeled POWER located at the bottom left of the Main Electronics Board. After the FloBoss unit
completes start-up diagnostics (RAM and other internal checks), the LCD displays the date and time
to indicate that the FloBoss unit completed a valid reset sequence. If the LCD does not come on, refer
to Section 9, Troubleshooting, for possible causes.
2.4.2 Operation
Once startup is successful, it is necessary to configure the FloBoss unit to meet the requirements of
the application. ROCLINK for Windows Configuration Software User Manual (Form A6091) details
the procedure for configuring the FloBoss unit and calibrating the I/O. Once the FloBoss unit is
configured and calibrated, it can be placed into operation.
Local configuration or monitoring of the FloBoss unit through its Local Port (LOI) must be
performed only in an area known to be non-hazardous. Performance of these procedures in
a hazardous area could result in personal injury or property damage.
During operation, the FloBoss unit can be monitored (to view or retrieve current and historical data)
either locally or remotely. Local monitoring is accomplished either by viewing the LCD panel by
using ROCLINK for Windows software on a PC connected through the LOI Local Port. Remote
monitoring is performed through the Host Port of the FloBoss unit, typically using host software.
Remote monitoring can also be performed using ROCLINK for Windows software.
For an analog I/O channel, the Duty Cycle is approximated by estimating the percent of time that the
channel spends in the upper half of its range (span) of operation. For example, if an Analog Input is
wired as a current loop (4 to 20 milliAmp) device and operates in the upper half of its range 75% of
the time, then 0.75 would be used as the Duty Cycle. If the Analog Input channel generally operates
around the midpoint of its span, use 0.5 as the Duty Cycle.
To calculate the total power consumed by an I/O channel use Table 3-2 and read the minimum (Pmin)
and maximum (Pmax) power consumption value from the table for the desired I/O channel. Use the
following equation to calculate the power consumption for a channel with the Duty Cycle taken into
account:
Power = (Pmax x Duty Cycle) + [Pmin (1 – Duty Cycle)]
Multiply this value by the Quantity of I/O channels with the same Duty Cycle and enter the calculated
value in the Subtotal column. Repeat the procedure for all other I/O channels used. Total the values
in the Subtotal column in Table 3-2, and enter the value in the I/O Card row of Table 3-1.
Power Consumption
Subtotal
Device (mW) 12 V System Quantity Duty Cycle
(mW)
Pmin Pmax
FloBoss 503 Main Electronics
Board; includes minimum built-in
200 1 N/A
I/O power consumption, RTD, and
DVS or MVS
FloBoss 504 Main Electronics
Board; includes minimum built-in
500 1 N/A
I/O power consumption, RTD, and
Sensor Module
Built-in Discrete Output (load
dependent with a maximum of 15 0 4000 1
volts and 0.3 Amps)
Serial Communications Card 30 N/A
Dial-up Modem Comm Card 250 N/A
Radio N/A N/A N/A
I/O Card Total from Table 3-2
Total
Power Consumption
(mW) 12 V System Subtotal
Device Quantity Duty Cycle
(mW)
Pmin Pmax
I/O Card – base amount 210 210 1 N/A
Analog Input 90 365
Analog Output 130 650
Discrete Input 0 110
Discrete Output 0 30
Pulse Input 0 70
Total
Notes: 1. For analog I/O channels, the Duty Cycle is the percent of time spent in the upper half of the operating range.
2. The Pmax amount includes any power drawn by a FloBoss-powered field device, such as a transmitter.
Power Consumption
(mW) 12V System Subtotal
Device Quantity Duty Cycle
(mW)
Pmin Pmax
I/O Card – base amount 1560 1560 1 N/A
Analog Input 0 264
Analog Output 0 264
Discrete Input 0 14.4
Discrete Output 0 28.8
Discrete Output Relay 0 204
Pulse Input 0 48
Total (Pmax with all DO is 4930 mW)
To calculate the total power consumed by a radio, obtain the power (P) consumption values for
transmit and receive from the radio manufacturer’s literature. Use the following equation to calculate
the power consumption for a particular Duty Cycle:
Power = (PTX x Duty Cycle) + [PRX (1 – Duty Cycle)]
Determine the power consumption for all radios that use power from the FloBoss unit, and enter the
total calculated value in Table 3-1.
Proper grounding of the FloBoss unit helps to reduce the effects of electrical noise on the unit’s
operation and protects against lightning. Lightning protection is designed into the FloBoss unit,
providing lightning protection for built-in field wiring inputs and outputs. A surge protection device
installed at the service disconnect on line-powered systems offers lightning and power surge protection
for the installed equipment. You may also consider a telephone surge protector for the dial-up modem
communications card.
All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured
with a ground system tester. The grounding conductor should have a resistance of 1 ohm or less between
the FloBoss case ground lug and the earth ground rod or grid.
The grounding installation method for the FloBoss unit depends on whether the pipeline has cathodic
protection. On pipelines with cathodic protection, the FloBoss unit must be electrically isolated from the
pipeline.
Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the
meter run. In this case, the FloBoss unit could be flange mounted or saddle-clamp mounted directly on
the meter run and grounded with a ground rod or grid system.
Do not connect the earth ground to any wiring terminal on the Main Electronics Board. It
could result in property damage.
Finally, the number of solar panels can be determined using the following equation:
Number of Panels = Iarray Amps / (Ipanel Amps/panel) = _____ panels
For example, if Iarray equals 0.54 Amps, and Ipanel equals 0.29 Amps for a 5-watt panel, then the
number of panels required equals 1.86, which would be rounded up to 2 (panels connected in parallel).
Alternatively, the next larger solar panel can be used, which in this case would be a 10-watt panel.
Table 3-4 gives recommended Ipanel values for solar panels.
NOTE: The I panel value varies depending on the type of solar panel installed. Refer to the
vendor’s specifications for the solar panel being used.
NOTE: The current accepted by the FloBoss 500-series unit is limited by its charging circuit to
around 1 Amp. Therefore, it is not practical to install a solar array that supplies significantly
more than 1 Amp to the FloBoss unit.
Panel I panel
4.5 watt 0.27 Amps
5 watt 0.29 Amps
10 watt 0.58 Amps
11 watt 0.7 Amps
3.1.7 Batteries
Batteries are used to supplement both line-powered and solar-powered installations. When used in
line-powered installations, the batteries serve as backup in case of line power failure. When used in
solar installations, they provide power for the FloBoss unit when the solar panels are not generating
sufficient output.
The standard battery configurations use a 12-volt, sealed, lead-acid battery (approximately 6.0 x 2.6 x
3.7 inches). These configurations can provide 7, 14, 21, or 28 Amp-hour capacities. Recommended 7
Amp-hour battery types (up to four batteries) for FloBoss 500-series units are listed below. If other
batteries are used, rechargeable, sealed, gel-cell, lead-acid batteries are recommended.
♦ Powersonic PS-1270 7.0 Amp-Hour
♦ Panasonic LCR12V7.2P 7.2 Amp-Hour
♦ Yuasa NP7-12 7.0 Amp-Hour
The batteries are connected in parallel by a supplied wiring harness to achieve the required capacity.
The amount of battery capacity required for a particular installation depends upon the power
requirements of the equipment and days of reserve (autonomy) desired. Battery requirements are
calculated based on power consumption of the FloBoss unit and all devices that will be powered by
the batteries.
Battery reserve is the amount of time that the batteries can provide power without discharging below
20 percent of their total output capacity. For solar-powered units, a minimum reserve of five days is
recommended, with ten days of reserve preferred. Add 24 hours of reserve capacity to allow for
overnight discharge. Space limitations, cost, and solar panel output are all factors that affect the
actual amount of battery capacity available.
To determine the system capacity requirements, multiply the system current load (ISF) on the batteries
by the amount of reserve time required. Compute “ISF” as described in Section 3.1.3, Totaling Power
Requirements, on page 3-3. The equation is as follows:
System Requirement = ISF Amps × Reserve hours = _____ Amp-hours
Finally, determine the number of batteries required for the calculated power consumption by rounding
up to the nearest multiple of 7 Amps: 7, 14, 21, or 28 Amp-hour capacity. If more than 28 Amp-hours
are required, an external battery enclosure with additional batteries may be used.
Always turn off the power to the FloBoss unit before you attempt any type of wiring.
Wiring of powered equipment could result in personal injury or property damage.
To avoid circuit damage when working with the unit, use appropriate electrostatic discharge
precautions, such as wearing a grounded wrist strap.
Definition Connector
Battery Input POWER (+BAT–)
Charge Input POWER (+CHG–)
Auxiliary Radio Power RADIO
Flow Sensor P/DP
Discrete Output DO
Resistance Temperature Detector RTD
Local Port LOI
Communications Card connector P3
I/O Card connector P5
The input terminal wiring is arranged on the lower edge of the Main Electronics Board. The terminal
designations are printed along the bottom of the circuit board.
Do not connect the earth ground to any terminal on the Main Electronics Board. It could
result in property damage.
For line-powered installations, the grounding conductor must end at the service disconnect.
The grounding conductor can be wire or metallic conduit, as long as the circuit provides a
low-impedance ground path.
grnd503
Earth Ground
P8
Up to 15 volts Up to 22 volts
POWER
+BAT- +CHG-
FB500PWR
Remove the removable Power terminal block before removing the battery connections or the
battery. Power being sent to the FloBoss unit without batteries in operation could damage
the FloBoss unit.
The maximum voltage that can be applied to the “BAT” terminals without damage to the
electronics is 15 volts dc. Excessive voltage could result in property damage.
The FloBoss enclosure can hold up to four sealed lead-acid batteries. Refer to Section 3.1.7,
Batteries, for recommended battery types. The 12-volt batteries can be installed to provide 7, 14, 21,
or 28 Amp-hours of backup capacity, or up to 21 Amp-hours of backup capacity when used with an
AC power supply.
The batteries are mounted under the electronics swing-out mounting panel and are retained by the
panel when it is secured. The AC Power Supply mounts in place of one of the batteries. The batteries
are connected to a harness that allows the batteries to be changed without removing power from the
unit. Make sure that the black wires of the harness are connected to the negative terminals of the
batteries and the red wires are connected to the positive terminals. Input wiring is connected at the
POWER wiring terminal connector.
P8 P9
P11
Solar
Panel
Swing-out
Panel
DOC0361A
Remove the removable Power terminal block before removing the battery connections or the
battery. Power being sent to the FloBoss unit without batteries in operation could damage
the FloBoss unit.
Power
Supply
DOC0306B
AC POWER
The AC Power Supply is shipped ready for 115 volt operation. It may be changed to 230 volt
operation. To change the voltage input:
1. Loosen the four ¼-inch hex head screws (two above and two below).
2. Pull the AC Power Supply straight out to remove the AC Power Supply.
3. Move the Switch S1 on the back of the AC Power Supply to the desired position.
4. Re-install the AC Power Supply.
In installations where battery backup is used, the AC Power Supply also functions as a battery
charger. When charging batteries, temperature compensation of the output voltage is provided.
Battery temperature is sensed by a thermistor (supplied) connected to terminals T1 and T2 on the AC
Power Supply For connection to the FloBoss when battery backup is being used, refer to Figure 3-6.
If battery backup is not used, ensure that the DC output of the AC Power Supply is connected to the
+CHG– terminals.
POWER INTENAL
TERMINAL BLOCK POWER SUPPLY
- + -
+ - +
BAT CHG
+ - + - DC AC
OUTPUT INPUT
5 Amp - + L1 L2 GR
ac_sch2 Fuse
aux_dir
+ BAT - + CHG - + -
- Radio, cell phone, or
other constant-powered
+ device
Common RX TX
P8 P9 P10
P11
Red (TX)
White (RX)
Black
(Common)
Connections at
PC Serial Port
DOC0356A
P1 Mating Connector
C1
FB1
C2
U1
CR1
R1
DCD
C3
CR2 C4
R2
RXD
R4 U2
R3
CR3
R5 Q1
TXD
R6
LEDs R8 R9 C5
CR4 R7
C6
Q2
RTS
FB2 C7
F2
CR5
GND
DCD
RXD
DTR
TXD
RTS
DTR
IN
TB2 TB3
Power Control Host Port Terminals
Terminals
DOC0274A
P1 Mating Connector
C1
C2
FB1
CR1
TXD R1 U1
FB2
C3
CR2
R2
RXD
LEDs U2
C4
CR3
CR4 CR5
RTS
R3
R4
PTR1 B A GND PTR2
TB1
DOC0275A
J1
PCB
U1 C2
U2
C3
FB2
C4
FB1
R1 R2 R3
CR1
RXD
CR2 CR4
FB3 FB4 C6
TXD
CR3
RI
C5
PTR1 J2 PTR2
DOC0415A
Note: The communications modem module was upgraded in September of 2011 with a new
modem component (U2), available in model W28146X0022. The new modem component is
smaller and shows a portion of the printed circuit board (PCB) (see Figure 4-4).
The modem card interfaces to 2-wire, full-duplex telephone lines using asynchronous operation at data
baud rates of 1200 and 2400. The card interfaces to a PSTN through an RJ11 jack located at the
bottom of the communications card. Control the modem using industry-standard AT command
software. A 40-character command line is provided for the AT command set.
Note: Set the modem initialization strings with the appropriate AT command (Config
Command) in the Modem screen within ROCLINK configuration software. The Config
Command for the FloBoss 503 and 504 is:
♦ ATEØHØVØX1QØ&C1&D2&SØ&LØSØ=1S7=60 (for modem model W28146X0012)
♦ ATEØHØVØX1QØ&C1&D2&SØSØ=1S7=60 (for modem model W28146X0022)
LED indicators on the communications card show the status of the RXD, TXD, and RI control lines
(see Table 4-2). The modem card also provides EIA-232 (RS-232) level output signals (RXD and
TXD) for an analyzer.
When installing units in a hazardous area, ensure that the components selected are labeled
for use in such areas. Change components only in an area known to be non-hazardous.
Performing these procedures in a hazardous area could result in personal injury or property
damage.
Be sure to use proper electrostatic handling, such as wearing a grounded wrist strap, or
components on the circuit cards may be damaged.
NORM
RST
P1
C3
P1
U2
Mating
Connector
Stand-off Hole P5
U6
Communications
CR1 U8 Card
DCD
U9
CR2
RXD
CR3
TXD
CR4
RTS
CR5 U11
GND
DCD
DTR
RXD
DTR
TXD
RTS
TB2 TB3
CR6 CR7
PT2 PT3
FL1 PT1 MV1
CR9 MV2
P9 P10
P8 P11
DOC0332B
Terminal Function
RXD Receive data
TXD Transmit data
DTR Data Terminal Ready
RTS Ready to Send
DCD Data Carrier Detect
GND Ground
IN Switched Power Input
Out Switched Power Output
EIS-232 (RS232)
TXD
Communications
Card
RTS
GND
DCD
RXD
DTR
TXD
RTS
DTR
+ Switched
- Power to Radio
aux_swch
Refer to Section 3, Power Connections, for additional information concerning auxiliary power.
Terminal Function
A EIA-485 (RS-485) Positive
B EIA-485 (RS-485) Negative
GND Ground
Multiple units with communication cards installed may be daisy-chained together without exceeding
1220 m (4000 feet). When daisy-chaining communication cards, they should be connected in a
sequential order. For example, comm card one should connect to comm card two and comm card two
should connect to comm card three.
RJ11 Signal
1 –
2 –
3 Tip
4 Ring
5 –
6 –
When repairing units in a hazardous area, make sure that the components selected are
labeled for use in such areas. Change components only in an area known to be non-
hazardous. Performing these procedures in a hazardous area could result in personal injury
or property damage.
Be sure to use proper electrostatic handling, such as wearing a grounded wrist strap, or
components on the circuit cards may be damaged.
During this procedure, all power will be removed from the FloBoss and devices powered by
the FloBoss. Make sure that all connected input devices, output devices, and processes will
remain in a safe state, when power is removed from the FloBoss and when power is restored
to the FloBoss. An unsafe state could result in property damage.
1. As a precaution, save the current configuration and historical data to Config Memory. Use
Write to Internal Config Memory (ROC menu > ROC Flags) in ROCLINK for Windows
software.
2. Remove the Power terminal block at P8 on the Main Electronics Board.
3. If the communications card is a modem card, unplug the RJ11 phone jack cable from the
communications card connector J2.
4. Using a rocking motion, gently disengage the two stand-off connectors located at the bottom
of the communications card.
5. Using a rocking motion, gently disengage the stand-off connector located at the top, in the
middle of the communications card.
6. Using a rocking motion to disengage the connectors at P1, pull the card free from the Main
Electronic Board at P3.
7. To reinstall a communications card, orient the card with the P1 connectors on the
communications card mating with the connectors at P3 on the Main Electronics Board. Plug
the card into its stand-off connectors and gently press until the connectors firmly seat.
8. For a modem card, connect the RJ11 phone jack cable to communications card connector J2.
9. Reconnect power by plugging in the Power terminal connector at P8 on the Main Electronic
Board.
10. Check the configuration data and FSTs, and load or modify them as required.
11. Verify that the FloBoss 500-series performs, as required.
If you changed the configuration, save the configuration data to Flash ROM. If you changed the
configuration, history database, or FSTs, save them to disk. Refer to the ROCLINK for Windows
Configuration Software User Manual (Form A6091) for more information.
5.1 Description
The FloBoss units have a built-in RTD Input, a Discrete Output (DO), and three diagnostic Analog
Inputs.
The FloBoss 500-series Input/Output (I/O) cards, shown in Figure 5-1, Figure 5-2, and Figure 5-3,
provide additional inputs and outputs for expanded monitoring and control applications. Table 5-1
displays the types of additional I/O channels for the FloBoss 500-series units that the I/O Cards
provide. Two types of optional I/O Cards are available: 10-channel and 24-channel.
The I/O Cards use a microprocessor for monitoring, control, and acquisition of data from external
devices connected to the I/O channels. The information is then relayed to the FloBoss 500-series
unit. The I/O channels have removable plug-in terminal blocks for field wiring. In addition, the 10-
channel card has six LEDs to indicate the state of the Discrete Inputs, Discrete Outputs, and Pulse
Inputs. Refer to Section 5.4, I/O Card LEDs.
or Screw U1
PI/2
+
FB2
J1 R3
COM
CR2 P1
C2
PI/1
R4
+
U4 R5
CR3
R6
LEDs
DI/2
+
R7
COM
R8
CR4 P2
R12 U5 R9
DI/1
U3
R11
+
FB3 R10
R13 CR5
R15 R14 C3 CR6
DO/2
-
1
C4
2
P3
Y1 U6 CR7
R16
+
FB4 R17 R18
R19 CR8
C5 C6
U7 PT1 CR9 P4
DO/1
-
CR10
CR12
CR13
+
R20 CR11
Main Board FB5
Connector R21
C7
U8 PT2 Screw
-
U11
AI/3
U10
R22
+
C8 CR14
J2
R23 R24
P5
R26
+T
U9
R25 CR16 CR17
FB6 C9
1
2
U13 CR15
U12
C10
-
FB7 C13 U14 R28
R27
AI/2
C14
C11 C12
+
CR18
R29 U16 P6
+T
U17 R30
R32 R33 R34
R31 CR19 CR20 CR21
R35 C15
R37 R38
R36 R41
-
U15 R39 U18 R40
AI/1
R42 R43
12 V / 24 V
+
CR22
R44
R49
R47 R48
+T
R45
U19 R46
P7
Jumper (on
FB9
FB8 C17
back of card)
P8 PT3
C16
AO
R52 CR23
Compression
W1
C18
+
R51 U22 C19
R53 P9
R50
CR24
U20 U21
Standoff Screw
12V
24V
or Screw
DOC0305B
A 10-channel I/O Card has no physical switches for the DI/PI selections. The DI/PI are selected
and the Point Numbers are configured in ROCLINK for Windows software.
The 10-channel I/O Card receives its power from the main processor card. The power converter
produces enough current to support four current loops (three AIs and one AO) plus the power to run
the analog-to-digital (A/D) and digital-to-analog (D/A) converters, as well as the Discrete Inputs.
The power converter can turn off under processor control to reduce the load in low-battery
conditions.
NOTE: The Pulse Inputs can be wired as a FloBoss-powered pulse counters. The pulse
circuitry is optically coupled to isolate the processor board from the input signal. The Pulse
Inputs on the 10-channel card can also be configured as Discrete Inputs.
Screw Screw
Main Board
Connector Screw
I/O Power
Screw Screw
A 24-channel I/O Card has sockets for AI scaling resistors provided on the back of the I/O Card,
along with switches for the selectable DI/DO channels. The DI/DO Point Numbers are configured
using ROCLINK for Windows software.
The 24-channel I/O Card receives its power from the main processor card. The processor is isolated
from noisy I/O circuits by optical coupling and a DC/DC power converter, which supplies power for
most of the I/O circuits. This converter helps isolate the field I/O from the processor.
If you require additional power for the I/O, connect an external 24 V dc power source to the +T and
–T on the I/O Power terminal block.
If you require additional voltage for the I/O, connect an external DC/DC to the +B, –B, +T, and –T
on the I/O Power terminal block.
NOTE: The isolation jumpers on the back of the 24-channel I/O Card (W1 and W2) should
both be set at BATT when providing battery power to the Discrete Inputs. Refer to Figure
5-3.
AI Scaling
Resistor R1
DI/DO Selector
Switch
AI Scaling
Resistor R8
Isolation
Jumpers
To avoid circuit damage when working with the unit, use appropriate electrostatic
discharge precautions, such as wearing a grounded wrist strap.
Always turn the power to the FloBoss off before you attempt any type of wiring. Wiring of
powered equipment could result in personal injury or property damage.
1. As a precaution, save the current configuration and historical data to Config Memory (Write
to Internal Config Memory) on the ROC > Flags screen of ROCLINK for Windows
software.
2. Unplug the Power terminal block at P8 on the Main Electronics Board to remove power.
When power is applied to the FloBoss, scanning of the I/O Card automatically activates. Use the
ROCLINK for Windows software to configure the new I/O points, history database, and other aspects
as desired. Refer to the ROCLINK for Windows Configuration Software User Manual (Form
A6091).
W11043A
Label
Mounting
B10
Screw
PI/2
12
PI/1
B9 11
DI/2
B8
DI/1
B7
DO/2
B6
Mating
DO/1
B5
Connector Mounting
Location Screw
AI/3
B4
AI/2
B3
AI/1
B2
AO
B1
Mounting
P8 P9 P10
Screw
P11
DOC0308B
Detent
Figure 5-5. I/O Card Installation (10-channel Card Shown)
Mounting
Screw Mounting
Screw
Mounting Mounting
Screw Screw
DOC0365B
Point / Label
Analog Input
Number
4 B1
5 B2
6 B3
7 B4
8 B5
9 B6
10 B7
11 B8
Terminal Function
+T Current-limited positive battery voltage for transmitter power
+ Positive Input
–T Negative Input (Common)
The Analog Inputs have three field terminals per channel. Refer to Table 5-4. When using a 10-
channel card, the “+T” terminal provides power for loop-powered devices at either 12 or 24 volts,
depending on the position of jumper W1 (not included on some of the first I/O Cards manufactured).
As in Figure 5-1, the jumper is actually found on the non-component side of the board. The “+T”
terminal on the 24-channel I/O Card currently provides 12 volts.
Each channel has a current regulator in series with the “+T” terminal to provide short-circuit
protection. A 250-ohm scaling resistor is supplied for use between the “+” and “–” Analog Input
terminals.
The “+” terminal is the positive signal input and the “–” terminal is the signal common. These
terminals accept a voltage signal in the 1 to 5 volt range. Because the “–” terminal is internally
connected to common, the Analog Input channels function as single-ended inputs only.
Current inputs of 4-20 milliAmps can be used with the addition of a 250-ohm resistor across the input
terminals. When wiring a 4-20 milliAmp current signal on the 10-channel I/O Card, leave the 250-
ohm resistor installed between the “+” and “–” terminals. The 24-channel I/O Card has 250-ohm
resistors in the sockets on the back of the card. Remove any resistors that will not be required. For
both I/O Cards, wire the current loop device “+” lead to the “+T” terminal and the device “–” lead to
the AI “+” terminal. Figure 5-7 shows the wiring for a typical current signal.
NOTE: FloBoss-powered means power is received from the Input, Output, or Module shown.
External or self-powered means power is received from the device, a battery, the FloBoss
Main Electronics Board, or another source.
NOTE: When connecting the Analog Input channel to a voltage device, be sure to remove
the 250-ohm resistor from the Analog Input terminal block. Figure 5-9 shows wiring for a 3-
or 4-wire voltage transmitter
* Note: This device should not receive power from the Main Electronic Board or a ground
loop may occur.
AI
FLOBOSS-POWERED POWER
Vs
3 OR 4 WIRE +T Current Limit
TRANSMITTER SIGNAL +
+ +
(1 TO 5 VOLTS)
COMMON
SELF-POWERED - -
DEVICE SIGNAL -
+T = 12/24 VDC, 22 mA max.
+SIGNAL = 1 TO 5 VDC
DOC0098A-J
Terminal Function
+ Positive load
– Negative load
A schematic representation of the field wiring connections to the Analog Output channel is shown in
Figure 5-10. The AO can provide loop current to non-powered field devices. The Analog Output
provides a 0 to 22 milliAmp current source output at terminal “+”. Terminal “–” is isolated from the
FloBoss common. Refer to Table 5-7.
Figure 5-10 shows wiring for a FloBoss-powered current loop device.
NOTE: FloBoss-powered means power is received from the Input, Output, or Module shown.
External or self-powered means power is received from the device, a battery, the FloBoss
Main Electronics Board, or another source.
AO
+ I
+ CONTROL
FLOBOSS-POWERED
LOOP DEVICE -
-
DOC0311A
Figure 5-10. Analog Output Field Wiring for Current Loop Devices
Terminal Function
+ Positive Discrete Input
COM Common
When using a 10-channel I/O Card, the I/O Card Discrete Inputs acquire power from the 24-volt
power supply. An LED indicator is included for each point on the field side. The signal from the
field is coupled through an optical isolator providing 2500 V dc isolation from the main FloBoss
circuit board.
NOTE: The 24-channel I/O Card does not have LEDs.
The Discrete Input operates by providing a voltage across terminals “+” and “COM” (Figure 5-11),
which is derived from internal voltage source (Vs). When a field device, such as a relay contact is
connected across “+” and “COM,” the closing of the contacts completes the circuit which causes a
flow of current between Vs and ground at terminal “COM.” This current flow activates the LED and
is sensed in the DI circuitry that, in turn, signals the FloBoss electronics indicating that the relay
contacts have closed. When the contacts open, current flow is interrupted and the DI circuit signals
to the FloBoss electronics that the relay contacts have opened.
The Discrete Input is designed to operate only with non-powered discrete devices, such as
“dry” relay contacts or isolated solid state switches. Use of the DI channel with powered
devices may cause improper operation or damage to occur.
NOTE: FloBoss-powered means power is received from the Input, Output, or Module shown.
External or self-powered means power is received from the device, a battery, the FloBoss
Main Electronics Board, or another source.
I/O Card
(Optional)
PI/1 - PI/2
COM
+
DI/1 - DI/2
COM Switch
+
NC
DOC0447A
The 10-channel I/O Card provides two Discrete Output channels at B5 and B6. The Discrete Output
channel is a normally-open, single-pole, single-throw switch. An LED turns on to show when the
switch is closed. The Discrete Outputs are solid-state switches enabled by individual signals from the
processor I/O lines. The solid-state switches are capable of handling 24 V dc at 300 mA.
The 24-channel I/O Card provides two dedicated Discrete Output mechanical relay channels at B9
and B10. The 24-channel I/O Card provides eight selectable DOs, which can also be configured as
DIs. The DO relays provide normally-open contacts, while the selectable DOs are normally-open,
solid-state switches that are used for activating externally-powered devices.
Table 5-11 and Table 5-12 display the Discrete Output’s number, the Point Number to which the AO
is assigned in ROCLINK for Windows software, and the number printed on the I/O Card. In the case
of the 24-channel card, the number in the software and on the label are the same.
Discrete
Point Number Label Number
Output
4 B5 DO/1
5 B6 DO/2
Terminal Function
+ Positive load
– Negative load
When using a 24-channel card, the external device must be powered directly from the battery or the +
terminal of the Radio Power Control terminal block. When using a solid state selectable Discrete
Output, the card must be placed in BATT mode (W1 and W2 jumpers located on the back of the
board). The negative terminal is not applicable for the selectable DO because the + terminal is in one
of two states: not connected or short to BATT ground (–).
Figure 5-13 shows a typical Discrete Output wiring diagram for solid-state relays.
NOTE: FloBoss-powered means power is received from the Input, Output, or Module shown.
External or self-powered means power is received from the device, a battery, the FloBoss
Main Electronics Board, or another source.
DO
+5V
+
SELF-POWERED +
DISCRETE DEVICE -
-
CONTROL
DOC0098A
Figure 5-14 shows a typical Discrete Output wiring diagram for mechanical relays.
DO
+
SELF-POWERED NO VS
DISCRETE DEVICE -
–
CONTROL
B9-B10
Function Output
Output Voltage during ON state Battery voltage minus 0.7 volts
Output Voltage during OFF state 0 volts
Maximum Output Current 0.3 Amp
Maximum Voltage 22 volts (clamping occurs at this voltage)
Because the output is not isolated, care must be used to ensure that the operation of the load does not
affect the operation of the FloBoss unit. This may include installation of back-EMF diodes and
MOVs on the load. The load should be connected as in Table 5-15.
Terminal Function
DO+ Positive load
DO– Negative load
P9 P10
P8 P11
DOC0358A
Odorizer,
Sample Valve,
or such
The Pulse Inputs provided on the 10-channel I/O Card are located at Point Number B11 and B12.
The Pulse Input at Point Number B11 can operate at up to 50 Hz, with a maximum 50% duty cycle.
The Pulse Input at Point Number B12 can operate at up to 10 kHz, with a maximum 50% duty cycle.
NOTE: The Discrete Inputs located at Point Number B9 and Point Number B10 require the
use of the two Pulse Inputs on the 10-channel I/O Card. Refer to Section 5.3.5.1, How to Use
Pulse Inputs as Discrete Inputs, on page 5-20.
The PI channel has two field terminals. One terminal is a positive source voltage and the other is the
signal return. The terminals are designated as in Table 5-18.
Terminal Function
+ Positive Pulse Input (Sourced)
COMM Common
EXTERNAL/FloBoss +
+
POWERED VS
-
PULSE DEVICE COM
B11/12 6.65K
DOC0310B
The Point Number designation can be viewed when using ROCLINK for Windows software (Figure
5-19); in addition, these Point Numbers appear on a label to the left of the terminals on the I/O Card.
NOTE: When using a PI as a DI, be careful to configure the correct Point Number. It may
help to name the Pulse Input Tag field DISCRETE so you do not accidentally try to configure
the Pulse Input when it is attached to a Discrete Input device.
To use a Pulse Input as a Discrete Input:
1. Make sure the I/O Card is installed correctly. Refer to Section 5.2, How to Install an I/O
Card, on page 5-4.
2. Attach a PC to the LOI port on the FloBoss and launch ROCLINK for Windows software.
3. In ROCLINK for Windows, connect to the FloBoss 500-series unit.
4. Select Configure > I/O > DI Points.
5. Select:
♦ Discrete Input 3 (Point Number B9 to use PI/1 as a DI) in the Point Number field. Refer
to Figure 5-19.
♦ Discrete Input 4 (Point Number B10 to use PI/2 as a DI) in the Point Number field.
Refer to Figure 5-19.
6. Type a name in the Tag field and configure the rest of the Discrete Input as detailed in the
ROCLINK for Windows Configuration Software User Manual (Form A6091).
7. Wire the channel for the Discrete Input the same as described in Section 5.3.1, Discrete
Inputs, on page 5-11.
NOTE: There is no jumper or software switch to set to change a PI into a DI or back again
Both software Point Numbers (such as B9 and B11) always exist for the same channel (in
this case, PI/1). Make sure that the PI or DI point is configured for the channel’s intended
use.
Terminal Function
REF Current Source Reference
+ Signal Positive Input
– Signal Negative Input
RET Return (Common) Reference
Red
Red
As shown in Figure 5-20, the connections at the RTD terminals for the various RTD probes is defined
as in Table 5-22.
Always turn off power to the FloBoss 503 before you connect or disconnect wiring. Wiring of
powered equipment could result in personal injury or property damage.
6.4 Configuration
Use the ROCLINK for Windows configuration software to configure the DVS Sensor, meter run, and
I/O. For more information, refer to the ROCLINK for Windows Configuration Software User Manual
(Form A6091).
Point
Input Type Reading
Number
Analog Input A1 Differential Pressure
Analog Input A2 Static Pressure (Gauge or Absolute)
RTD A3 Resistance Temperature Detector
The defaults contained within the Sensor are the initial pressures read. Refer to the Specifications
table on page 6-4 or the lable for the initial ranges. You can change the ranges through the calibration
routines. The turndown on the range should not be greater than the values in the Specifications table
on page 6-4.
The Sensor also supports the conversion of values to metric units. To enter the metric mode, use
ROCLINK for Windows software.
Point
Input Type Reading
Number
Analog Input A1 Auxiliary Pressure
Analog Input A2 Line (Static) Pressure
Pulse Input A5 Pulse Count
Pulse Input A6 Auxiliary Pulse Input
Standard PI and AI alarming are implemented, along with sensor and flow alarms. If the sensor fails
to communicate, either during initialization or run time, the Failure bit in the Pulse Input and Analog
Input alarm code is set. If alarms are enabled, an alarm is also entered in the Alarm Log.
The sensor measurement in the SM for the static and auxiliary pressure inputs can be any combination
of these ranges listed in Section 7.5. Read the label on the SM to know the specific pressure ranges.
The SM informs the Main Electronics Board that it is ready for an update at least once per second.
The FloBoss converts this value and stores it in the proper Pulse Input and Analog Input for access by
other functions within the FloBoss. If an update does not occur in ten seconds, the sensor is re-
initialized. A Point Fail alarm is set if the sensor does not respond to the initialization. Calibration is
performed through the PI and AI routines.
As described in Section 7.4, use ROCLINK for Windows Configuration Software to configure all
Analog Input and Pulse Input points required for turbine metering. Refer to the ROCLINK for
Windows Configuration Software User Manual (Form A6091) for detailed information.
P8 P9 P10
P11
P/DP
POWER RADIO LOI DO RTD RTS
+BAT- +CHG- + - BLK WHT RED + - REF + - RET
PI 1 PI 2
STAT-G
RST-R S + COM S +
DOC0300C
Turbine Pulse
Turbine Pulse Input (PI #2 or
Input (PI #1 or Channel B)
Channel A)
Status LED
Point
Input Type Reading
Number
Pulse Input A5 Pulse Count
Pulse Input A6 Auxiliary Pulse Input
The Pulse Input circuitry is based upon a two-stage Schmidt trigger inverter. Also provided is a
source voltage for open collector/drain turbines and for dry contacts. This source voltage is a nominal
12 volts open circuit; it provides approximately one milliAmp in shorted or closed contact positions.
The source voltage is load dependent. Note that the circuit does not supply sufficient power for a
pre-amp.
Be sure to use a pipe thread compound suitable for stainless steel, or galling may occur.
DOC0299B
Ribbon Cable
Always turn off the power to the FloBoss unit before you attempt any type of wiring.
Wiring of powered equipment could result in personal injury or property damage.
To avoid circuit damage when working with the unit, use appropriate electrostatic discharge
precautions, such as wearing a grounded wrist strap.
The actual wiring connections for the Pulse Input counter depend on the application. Refer to the
following figures for typical hook-ups.
A FloBoss powered Pre-amp (such as an universal type) can be accommodated by wiring the device
as shown in Figure 7-3. If a dual pulse train is required, wire the second PI channel in the same
manner.
As shown in Figure 7-4, a FloBoss powered field device that uses a switch to ground (a “shorting”
switch) can be accommodated by wiring the device between the “+” and COM terminals and also
connecting the “S” and “+” terminals together. Note that although the power for the pulse device is
shown coming from power terminals on the FloBoss, another suitable 12-volt source could be used
(but not the “S” terminal on the SM Pulse Input).
The field device is assumed to be opening and closing an isolated switch of some type. The SM
supplies the power to handle this wiring scheme.
The pulse device is typically a self-powered device with a built-in amplifier.
NOTE: FloBoss-powered means power is received from the Input, Output or Module shown.
External/Self-powered means power received from the device, a battery, the FloBoss main
electronics board, or another source.
NOTE: On External/Self-powered wiring, locate an external fuse close to the power connector
on the battery, the FloBoss main electronics board, or another source.
7.4 Configuration
Use ROCLINK for Windows Configuration Software to configure the meter run and inputs associated
with the SM. For configuration procedures, refer to the ROCLINK for Windows Configuration
Software User Manual (Form A6091).
Figure 7-5. Turbine Meter Setup for FloBoss 504 (ISO 9951 shown)
Point
Input Type Reading
Number
Analog Input A1 Auxiliary Pressure
Analog Input A2 Static Line Pressure
RTS A3 Temperature on the FloBoss Main Electronics Board
Pulse Input #1 (Channel A) A5 Pulse Count*
Pulse Input #2 (Channel B) A6 Auxiliary Pulse Input*
“Pseudo” Pulse Input A7 Corrected Pulse Count created by the firmware for Level A metering*
* NOTE: When configuring parameters for the Pulse Input identified in the Meter > Setup, be sure to
setup the Conversion factor and Advanced parameters to match the flow calculation results
(MCF/Day or 1000 m3/Day). For example, if your turbine meter produces 100 pulses/ft3, then enter
100,000 in the Conversion field of the Pulse Input screen and select Rate Period, EU/day, and
Conversion Pulses/EU in the Pulse Input > Advanced parameters dialog. Otherwise, the calculation
of Instantaneous Flow and Instantaneous Energy will not be performed correctly. Refer to the
ROCLINK for Windows Configuration Software User Manual (Form A6091).
SECTION 8 – CALIBRATION
This section describes how to calibrate the FloBoss 503 and FloBoss 504 Flow Managers.
This section contains the following information:
Section Page
8.1 Calibrating the FloBoss ......................................................................8-1
8.2 Calibrating I/O....................................................................................8-7
4. If desired, select and specify a Calibration Report File. Select Yes to create a report text file
containing calibration and verification details. Select No to continue without creating a report.
If you select Yes, another dialog box appears.
5. Type the name of the Calibration Report File in the File name field and use the extension
.cal to represent calibration. The Calibration Report File is created in the default directory
C:/Program Files/ROCLINK for Windows/Data, unless you specify otherwise
another Directory/Drive before you click Save. The report can be viewed using a text editor.
6. Click Save.
If you are calibrating a pressure input, read the following Caution, and then isolate the Sensor from
the process. If you are calibrating a temperature input, proceed to Step 8.
Open the by-pass valve on the valve manifold prior to isolating the sensor from the process,
to protect the differential cell of the Sensor. This will keep one side of the differential sensor
from being subjected to high pressure while the other side has no pressure applied. This
should be done whether you are calibrating differential or static pressure. Refer to Figure
8-2 for the recommended sequence.
L H L H L H
Bleed L H
Bleed
High
Pressure
2
Open
Remains
3
Close
1
Close
7. If you are calibrating a pressure input, setup the pressure calibrator and make the necessary
connections to the Sensor.
8. If you are calibrating a temperature input, disconnect the RTD sensor and connect a decade
box (or comparable equipment) to the RTD terminals of the FloBoss.
9. Click Calibrate under the desired input to calibrate Diff Press, Stat Press, or Temperature.
This displays the Set Zero calibration window as in Figure 8-3.
10. Calibrate the zero value (0% of range) for Differential Pressure (orifice only), Static Pressure,
or Temperature. This should correspond with the 0% Count and is the low value for the meter
run. Enter applied value in the Dead Weight/Tester Value (in engineering units) field of the
Set Zero dialog. This should be a 0 (zero) value. For a pressure input, this would typically be
open to atmosphere. For static pressure on an absolute-pressure device, remember to enter the
actual current atmospheric pressure, such as 14.73 psi. Refer to Figure 8-3.
NOTE: The % Difference (Live - Test) / Span is the percentage of difference of the Live
Reading divided by the Span.
11. When the Live Reading is stable, click Set Zero to calibrate the zero reading. The Set Span
window appears as in Figure 8-4.
12. Calibrate the span value (100% of range) for Differential Pressure (orifice only), Static
Pressure, or Temperature. Enter the Dead Weight/Tester Value (in engineering units). This
should correspond with the 100% Count and is the high value to the input (the top end of the
expected operating range). To maintain rated accuracy, be sure to observe the turndown limits
listed in the Sensor Specifications table.
♦ If you are calibrating the Diff Press input, and the Sensor is configured for Downstream
operation, apply the calibrator pressure to the low (labeled “L”) side of the sensor. Enter
the value as positive and the Live Reading appears as a negative value. ROCLINK for
Windows software automatically compensates.
♦ Static pressure for Downstream is calibrated the same as for Upstream.
♦ For static pressure on an absolute-pressure device, add the actual atmospheric pressure,
such as 300 + 14.73.
13. When the Live Reading is stable, click Set Span to calibrate the high reading. The window
advances to the Set Midpoint 1 window as in Figure 8-5.
14. To perform a two-point calibration, click Done. Calibration for this input is complete.
17. To perform a three-point calibration, click Done. Calibration for this input is complete.
18. To calibrate additional midpoints, apply the desired pressure or temperature and enter the
applied value in the Dead Weight / Tester Value (such as 50% of range) field.
19. When the Live Reading is stable, click Set Mid 2 to calibrate this reading. The display
advances to the Set Midpoint 3 window as in Figure 8-7.
20. To perform a four-point calibration, click Done. Calibration for this input is complete.
Do NOT close the by-pass valve on the valve manifold until after process pressure has been
reapplied, to protect the differential cell of the Sensor. This will keep one side of the
differential sensor from being subjected to high pressure while the other side has no
pressure applied. Refer to Figure 8-8.
1a
Close
1b
Close
L H L H L H L H
4
Close
2
Open
3
Open
NOTE: If you calibrated the Differential Pressure input, refer to Section 8.1.1, Zero Shift,
before completing the last step.
23. Finally, click Done to cause the calibration window to close, cancel freeze values (unfrozen),
and enable live readings for use in the flow calculations. The Event Log records all calibration
settings that were changed.
For a FloBoss 504, the built-in inputs that are supported with the 5-point calibration are:
♦ Auxiliary pressure (optional) = AI Point Number A1.
♦ Static (line) pressure = AI Point Number A2.
♦ RTD temperature = AI Point Number A3.
These inputs are assigned to the first three Analog Input points. The calibration procedure for these
inputs is described in Section 8.1, Calibrating the FloBoss, on page 8-1.
SECTION 9 – TROUBLESHOOTING
This section provides generalized guidelines for troubleshooting of the FloBoss 503 and FloBoss 504.
The procedures in this chapter should be performed before removing power for any reason, after
restoring power, and if the unit is disassembled.
The ROCLINK for Windows software runs on the personal computer and is required for a majority of
the troubleshooting performed on the FloBoss unit. Refer to the ROCLINK for Windows
Configuration Software User Manual (Form A6091) for additional information.
The following tools are required for troubleshooting:
♦ IBM-compatible personal computer.
♦ ROCLINK for Windows software.
♦ Flat-head and Philips screwdrivers.
9.3 Procedures
6. Click Apply.
When working on units located in a hazardous area (where explosive gases may be present),
make sure the area is in a non-hazardous state before performing these procedures.
Performing these procedures in a hazardous area could result in personal injury or property
damage.
To avoid circuit damage when working inside the unit, use appropriate electrostatic
discharge precautions, such as wearing a grounded wrist strap.
1. Launch ROCLINK for Windows software.
2. Ensure that the configuration is saved in flash memory by performing a Write to Internal
Config Memory (ROC menu > Flags). This saves all configuration settings, including the
current states of the ROC Flags and calibration values.
3. If you will be replacing the flash chip, save the current configuration data to disk by using File
> Save. This action saves the configuration to an .fcf file (you can specify your own file name
and path if desired).
4. Select ROC > Collect Data.
5. Select the All checkbox and click OK. This action saves event logs (.evt), alarm logs (.alm),
report data (.det), hourly logs (.pdb), and daily (.day) logs. You can specify your own file
name and path if desired.
P1
NORM
RST
DOC0277U
Ensure all input devices, output devices, and processes remain in a safe state upon restoring
power. An unsafe state could result in property damage.
When working on units located in a hazardous area (where explosive gases may be present),
make sure the area is in a non-hazardous state before performing these procedures.
Performing these procedures in a hazardous area could result in personal injury or property
damage.
1. Reconnect power to the FloBoss unit by inserting the Power terminal plug into the P8 Power
connector.
2. Launch the ROCLINK for Windows software, log in, and connect to the FloBoss unit.
3. Verify that the configuration is correct. If it is not, continue by configuring the required
items. If major portions or the entire configuration needs to be reloaded, perform the
remaining steps.
4. Select File > Download.
5. Select the backup configuration file (has extension *.FCF). Refer to Figure 9-4.
6. Select the Configuration Points checkboxes you desire to download (restore). Refer to
Figure 9-5.
GLOSSARY OF TERMS
A
A/D – Analog to Digital.
AGA – American Gas Association.
AI – Analog Input.
AO – Analog Output.
Analog – Analog data is represented by a continuous variable, such as an electrical current signal.
AP – Absolute Pressure.
API – American Petroleum Institute.
ASCII – American Standard Code for Information Interchange.
AWG – American Wire Gauge.
B
BTU – British Thermal Unit, a measure of heat energy.
Built-in I/O – Input/Output channels that are fabricated into the ROC or FloBoss and do not require a
separate module. Also called “on-board” I/O.
C
C1D2 – Class 1, Division 2 hazardous area.
COMM1 – Port on the FloBoss that may be used for host communications. This port is built-in for
EIA-232 (RS-232) serial communications.
Configuration – Typically, the software setup of a device that can often be defined and changed by
the user. Can also mean the hardware assembly scheme.
CRC – Cyclical Redundancy Check for communications integrity.
CSA – Canadian Standards Association.
CTS – Clear To Send modem communications signal.
D
D/A – Digital to Analog.
DB – Database.
dB – Decibel. A unit for expressing the ratio of the magnitudes of two electric signals on a
logarithmic scale.
DCD – Data Carrier Detect modem communications signal.
E
EEPROM – Electrically Erasable Programmable Read Only Memory, a form of permanent memory.
EFM – Electronic Flow Metering or Measurement.
EIA-232 – Serial Communications Protocol using three or more signal lines, intended for short
distances. Also referred to as RS-232.
EIA-485 – Serial Communications Protocol requiring only two signal lines. Can allow up to 32
devices to be connected together in a daisy-chained fashion. Also referred to as RS-485.
EMF – Electro-motive force.
EMI – Electro-magnetic interference.
ESD – Electro-static discharge.
EU – Engineering Units. User-selected units of measure.
F
Firmware – Internal software that is factory-loaded into a form of ROM. In the ROC or FloBoss, the
firmware supplies the software used for gathering input data, converting raw input data calculated
values, storing values, and providing control signals.
Flash ROM – A type of read-only memory that can be electrically re-programmed. It is a form of
permanent memory (needs no backup power).
FloBoss – A specialized Remote Operations Controller (ROC), microprocessor-based unit from the
Flow Computer Division of Emerson Process Management that provides remote monitoring and
control.
G-2 Glossary Rev 04/04
FloBoss 503 and 504 Instruction Manual
FSK – Frequency Shift Keyed.
FST – Function Sequence Table, a type of program that can be written by the user in a high-level
language designed by Emerson Flow Computer Division. One or more FSTs can be set up in a
ROC or FloBoss.
G
GFA – Ground Fault Analysis.
GND – Electrical ground, such as used by the ROC power supply.
GP – Gauge Pressure.
H
HART – Highway Addressable Remote Transducer.
hw – Differential pressure.
I, J
ID – Identification.
IEC – Industrial Electrical Code.
IMV – Integral Multiplier Value.
I/O – Input/Output.
IRQ – Interrupt Request. Hardware address oriented.
IV – Integral Value.
K
Kbytes – Kilobytes (KB).
kHz – Kilohertz.
L
LCD – Liquid Crystal Display. Display only device used for reading data.
LED – Light-emitting diode.
LOI – Local Operator Interface. Refers to the serial EIA-232 (RS-232) Local Port on the ROC or
FloBoss through which local communications are established, typically for configuration software
running on a PC. Also referred to as Local Port or Op Port.
LRC – Longitudinal Redundancy Checking, a type of error checking.
M
mA – Milliamps.
MCU – Master Controller Unit.
MEB – Main Electronics Board.
Modular I/O – I/O channels that are provided on a ROC or FloBoss by means of I/O modules. See
I/O Module.
MPU – Micro-processor Unit.
MVS – Multi-Variable Sensor. The MVS provides differential pressure, static pressure, and
temperature inputs to the FloBoss or Remote MVS interface for orifice flow calculation.
mV – Millivolts, or 0.001 volt.
mW – Milliwatts, or 0.001 watt.
N
NEC – National Electrical Code.
NEMA – National Electrical Manufacturer’s Association.
O
OH – Off-Hook modem communications signal.
Off-line – Accomplished while the target device is not connected (by a communications link). For
example, off-line configuration is configuring a ROC in a electronic file that is later loaded into
the ROC.
Ohms – Units of electrical resistance.
On-line – Accomplished while connected (by a communications link) to the target device. For
example, on-line configuration is configuring a ROC while connected to it, so that current
parameter values are viewed and new values can be loaded immediately.
Opcode – Type of message protocol used by the ROC to communicate with the configuration
software, as well as with host computers.
P, Q
Parameter – A property of a point that typically can be configured or set by the user. For example,
the Point Tag ID is a parameter of an Analog Input point. Parameters are normally edited by using
configuration software running on a PC.
Pf – Flowing pressure.
PC – Personal computer.
P/DP – Pressure/Differential Pressure.
PI – Pulse Input.
R
Rack – For a ROC, a rack is a row of slots into which I/O modules may be plugged. The rack is
given a letter to physically identify an I/O channel location, such as “A” for the first rack. Built-in
I/O channels are assigned a rack identifier of “A,” while diagnostic I/O channels are considered to
be in rack “E”.
RAM – Random Access Memory. In a FloBoss, it is used to store history, data, most user programs,
and additional configuration data.
RBX – Report-by-exception. In a FloBoss, it always refers to Spontaneous RBX in which the
FloBoss contacts the host to report an alarm condition.
RFI – Radio frequency interference.
RI – Ring Indicator modem communications signal.
ROC – Remote Operations Controller, Emerson Process Management’s microprocessor-based unit
that provides remote monitoring and control.
ROCLINK for Windows – Configuration software used to configure ROC or FloBoss units to gather
data, as well as most other functions.
ROM – Read-only memory. Typically used to store firmware. Flash memory.
RS-232 – Serial Communications Protocol using three or more signal lines, intended for short
distances. Also referred to as EIA-232.
RS-485 – Serial Communications Protocol requiring only two signal lines. Can allow up to 32
devices to be connected together in a daisy-chained fashion. Also referred to as EIA-485.
RTC – Real-time clock.
RTD – Resistance Temperature Detector.
RTS – Ready to Send modem communications signal.
Rev 04/04 Glossary G-5
FloBoss 503 and 504 Instruction Manual
RTU – Remote Terminal Unit.
RX or RXD – Received Data communications signal.
S
SAMA – Scientific Apparatus Maker’s Association.
Script – A uncompiled text file (such as keystrokes for a macro) that is interpreted by a program to
perform certain functions. Typically, scripts can be easily created or edited by the end-user to
customize the software.
Soft Points – A type of ROC point with generic parameters that can be configured to hold data as
desired by the user.
SP – Setpoint (when used in discussions of PID loops), or Static Pressure (when used in discussions
of flow parameters).
SPI – Slow Pulse Input.
SRAM – Static Random Access Memory. Stores data as long as power is applied; typically backed
up by a lithium battery or supercapacitor.
SRBX – Spontaneous Report By Exception.
SVA – Signal Value Analog.
SVD – Signal Value Discrete.
T-Z
TDI – Timed Discrete Input, or Timed Duration Input.
TDO – Timed Discrete Output, or Timed Duration Output.
Tf – Flowing temperature.
TLP – Type (of point), Logical (or point) number, and Parameter number. For a list and explanation
of the TLPs, refer to the ROC Protocol Manual (Form A4199).
TX or TXD – Transmitted Data communications signal.
INDEX
Symbols C
% Difference (Live - Act.) / Span............................... 8-3 C Prime....................................................................... 1-8
+T Jumper .................................................................. 5-9
0% Count Calculations
Set Zero ................................................................. 8-3 1992 AGA.............................................................. 1-9
10-Channel I/O Card ................................................. 5-2 1992 Flow .............................................................. 1-8
24-Channel I/O Card ................................................. 5-3 Input and Extension ............................................... 1-8
1992 AGA Instantaneous Rate ................................................. 1-8
Flow Calculations ........................................... 1-8, 1-9 Calibration ........................................................... 8-1, 8-7
32-bit CMOS Microprocessor .................................... 1-4 Report .................................................................... 8-2
Cathodic Protection .................................................... 3-5
A Charger ..................................................................... 3-12
AC Power Supply..................................................... 3-13 CHG ......................................................................... 3-11
Installation ........................................................... 3-14 Class I......................................................................... 2-2
Specifications....................................................... 3-16 Clock
Accessories................................................................. 1-5 Real-Time ............................................................ 1-18
AGA ........................................................................... 1-7 Cold Start............................................................. 9-3, 9-6
AGA8 ......................................................................... 1-9 Collect Data................................................................ 9-6
Alarm Log ................................................................ 1-11 Comm Port
Analog Inputs ............................................................. 7-4 Host Port (Comm1).............................................. 1-16
Troubleshooting..................................................... 9-3 Local Port (LOI) .................................................. 1-16
Wiring.................................................................... 5-8 Wiring Host Port (Comm1) ................................... 4-9
Analog Outputs Wiring Local Port (LOI)........................................ 4-1
Troubleshooting..................................................... 9-3 Comm1 ..................................................................... 1-16
Wiring.................................................................. 5-10 Troubleshooting..................................................... 9-2
Antennas..................................................................... 2-2 Wiring.................................................................... 4-9
API ............................................................................. 1-7 Communication Ports ............................................... 1-16
Approvals ................................................................... 2-2 Communications Cards
AT Command ............................................................. 4-6 Descriptions ........................................................... 4-2
Automatic Self Tests ................................................ 1-18 Dial-Up Modem..................................................... 4-5
Auxiliary EIA-232 (RS-232) ................................................. 4-3
Output Power....................................................... 3-15 EIA-485 (RS-485) ................................................. 4-4
Power..................................................................... 4-9 Installation ............................................................. 4-7
Pressure.................................................................. 1-7 LED Indicators ...................................................... 4-4
Average Archive Type ............................................. 1-10 Replacing ............................................................. 4-11
Specifications....................................................... 4-13
Troubleshooting the Dial-up Modem..................... 9-2
B Troubleshooting the Serial Communications......... 9-2
Backup........................................................................ 9-6 Wiring Auxiliary Power ........................................ 4-9
Base Multiplier Value Wiring Dial-Up Modem ...................................... 4-11
BMV ...................................................................... 1-8 Wiring EIA-232 (RS-232) ..................................... 4-9
BAT.......................................................................... 3-11 Wiring EIA-485 (RS-485) ................................... 4-10
Battery ................................................................. 1-6, 3-7 Wiring Host Port (Comm1) ................................... 4-9
Accessing the Compartment .................................. 2-7 Configuration.............................................................. 2-7
Capacity with Power Supply................................ 3-13 Dual-Variable Sensor............................................. 6-2
Charger ....................................................... 3-12, 3-13 Sensor Module....................................................... 7-7
Connections ......................................................... 3-11 Connect a Communications Card Wiring................... 4-9
Requirements ......................................................... 3-7
Board .......................................................................... 1-4 D
Daily Historical Logs ............................................... 1-11
DC Power Source ..................................................... 3-11
O R
Operation .................................................................... 2-8 Radio
Operator Interface Port ............................................. 1-16 Auxiliary Output Power ....................................... 3-15
Options........................................................................ 1-5 Bracket ............................................................1-5, 2-7
Overview .................................................................... 1-2 Mounting................................................................ 2-7
Power Cycling...............................................3-16, 4-3
P, Q Power Requirements .............................................. 3-3
P/DP.....................................................................6-2, 7-4 Wiring Switched Auxilary Power .......................... 4-9
Periodic Radio Frequency Interference..................................... 3-5
Timer Interrupt............................................. 1-19, G-5 RBX .......................................................................... 1-13
Periodic Log Real-Time Clock....................................................... 1-18
S T
Security.....................................................1-5, 1-12, 1-16 Table 1-1. History Points.......................................... 1-10
Intrusion Switch................................................... 5-13 Table 3-1. Power Consumption of the FloBoss and
Sensor Powered Devices ...................................................... 3-2
FloBoss 503 ........................................................... 6-1 Table 3-2. Power Consumption of the I/O Card........ 3-2
FloBoss 504 ........................................................... 7-1 Table 3-3. Power Consumption of the I/O Cards (24
Wiring DVS........................................................... 6-2 Channel) ................................................................... 3-3
Wiring SM ............................................................. 7-5 Table 3-4. Solar Panel Sizing .................................... 3-7
Sensor Module Table 3-5. Terminal Connectors................................ 3-8
Analog Inputs ........................................................ 7-4 Table 4-1. Local Port (LOI) Terminations ................ 4-1
Configuration......................................................... 7-7 Table 4-2. Communications Cards LED Indicators... 4-4
Configuration Inputs.............................................. 7-8 Table 4-3. EIA-232 (RS-232) Host Port Terminations
Connection............................................................. 7-4 .................................................................................. 4-9
Flow Calculations .................................................. 1-9 Table 4-4. EIA-485 (RS-485) Host Port Terminations
Inputs ..................................................................... 7-2 ................................................................................ 4-10
LEDs...................................................................... 9-5 Table 4-5. Dial-up Modem Host Port Terminations
Meter Run .............................................................. 7-7 ................................................................................ 4-11
Overview ............................................................... 7-1 Table 5-1. I/O Card Channels.................................... 5-1
Pulse Inputs............................................................ 7-3 Table 5-2. Analog Inputs – 10-Channel .................... 5-8
Specifications....................................................... 7-10 Table 5-3. Analog Inputs – 24-Channel .................... 5-8
Troubleshooting..................................................... 9-4 Table 5-4. Analog Inputs Terminals.......................... 5-9
Wiring.................................................................... 7-5 Table 5-5. Analog Outputs – 10-Channel................ 5-10
Serial Communications Table 5-6. Analog Outputs – 24-Channel................ 5-11
Troubleshooting..................................................... 9-2 Table 5-7. Analog Output Terminals....................... 5-11
Set Table 5-8. Discrete Inputs – 10-Channel................. 5-12
Midpoint ................................................................ 8-1 Table 5-9. Default Discrete Inputs – 24-Channel .... 5-12
Midpoint 1 ............................................................. 8-5 Table 5-10. Discrete Inputs Terminals .................... 5-12
Span ................................................................ 8-1, 8-4 Table 5-11. Discrete Outputs – 10-Channel ............ 5-14
Zero........................................................................ 8-1 Table 5-12. Default Discrete Outputs – 24-Channel
Setup ................................................................................ 5-14
Meter Run ....................................................... 6-2, 7-7 Table 5-13. Discrete Outputs Terminals.................. 5-15
Site Requirements....................................................... 2-2 Table 5-14. Discrete Output .................................... 5-16
Sleep Mode............................................................... 1-19 Table 5-15. Built-in Discrete Outputs Terminals .... 5-17
Software Watchdog .................................................. 1-18 Table 5-16. Pulse Inputs – 10-Channel.................... 5-18
Solar Panels ................................................................ 2-2 Table 5-17. Pulse Inputs – 24-Channel.................... 5-18
Power..................................................................... 3-5 Table 5-18. Pulse Inputs Terminals ......................... 5-18
If you have comments or questions regarding this manual, please direct them to your local sales representative
or contact:
Emerson Process Management
Flow Computer Division
Marshalltown, Iowa 50158 U.S.A.
Houston, TX 77065 U.S.A.
Pickering, North Yorkshire UK Y018 7JA
Website: www.EmersonProcess.com/flow